Navistar 9200 recalls by model year

Reported: 1997-07-28 (July 28, 1997) · Model years: 1996, 1997

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH SIX-SPOKE WHEEL ASSEMBLIES. THESE VEHICLES WERE MANUFACTURED WITH THE WRONG COMBINATIONS OF WHEEL ASSEMBLY PARTS. SHOULD THE SIX-SPOKE WHEEL ASSEMBLY HAVE MIS-MATCHED PARTS, HIGH STRESSES IN THE WHEEL STUDS AND POTENTIAL WHEEL FAILURES CAN OCCUR.

Consequence: STUD FAILURES CAN OCCUR RESULTING IN A WHEEL SEPARATION INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL INSPECT THESE WHEELS AND MAKE THE NECESSARY COMBINATION CORRECTIONS. ALSO OPERATOR INSTRUCTIONS AND VISUAL AIDS WILL BE UPDATED.

Reported: 1999-07-15 (July 15, 1999) · Model years: 1996, 1997, 1998

VEHICLE DESCRIPTION: TRUCKS ASSEMBLED WITH SKF LEVEL 2 TRUCK HUB UNITS (THU) RECEIVED FROM MERITOR. THESE HUBS CAN FATIGUE CRACK.

Consequence: THIS FATIGUE CRACKING CAN RESULT IN WHEEL SEPARATION, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THESE HUBS WITH PRODUCTION LEVEL 3 HUBS.

Reported: 1997-07-29 (July 29, 1997) · Model years: 1997

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH ANTILOCK BRAKE SYSTEM (ABS). THE WIRING FROM THE ELECTRONIC CONTROL UNIT WAS CONNECTED TO THE WRONG WHEEL SENSOR.

Consequence: SHOULD THE ABS WIRING BE CROSSED, IT WOULD RESULT IN A SIGNIFICANT DEGRADATION IN BRAKING STABILITY. A SIGNAL WOULD BE SENT TO THE WRONG BRAKE CHAMBER WHEN A BRAKE IMBALANCE IS DETECTED INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL INSPECT THE ABS WIRING AND PROPERLY CONNECT THE WIRES, IF NECESSARY.

Reported: 1997-11-24 (November 24, 1997) · Model years: 1997

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH DESIGN LEVEL 1, ROCKWELL FF980 SERIES FRONT AXLE. THE FRONT AXLE HUB FLANGE CAN DEVELOP CRACKS DUE TO HIGH STRESS LEVELS.

Consequence: CRACKS IN A HUB FLANGE CAN RESULT IN A WHEEL SEPARATION.

Remedy: DEALERS WILL REMOVE AND REPLACE THE FRONT HUBS WITH AN IMPROVED DESIGN LEVEL 2 HUB.

Reported: 1998-03-25 (March 25, 1998) · Model years: 1997, 1998

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH CATERPILLAR C-10 OR C-12 ENGINES. A BRACKET OR P-CLAMP AT THE REAR OF THE ENGINE THAT SUPPORTS THE COMPRESSOR DISCHARGE LINE WAS OMITTED.

Consequence: IF THE COMPRESSOR DISCHARGE LINE FAILS, THE AIR SYSTEM COULD BE DEPLETED AND CAUSE THE PARKING BRAKES TO APPLY. THIS CONDITION CAN CAUSE THE VEHICLE TO SLOW DOWN OR STOP UNEXPECTEDLY, CAUSING A VEHICLE CRASH WHICH COULD RESULT IN PROPERTY DAMAGE AND/OR PERSONAL INJURY.

Remedy: DEALERS WILL INSTALL P-CLAMPS AND A BRACKET AT THE REAR OF THE ENGINE.

Reported: 1998-05-27 (May 27, 1998) · Model years: 1997, 1998

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH PROSLEEPER BUNKS. A MICRO RELAY LOCATED BEHIND THE HVAC CONTROL PANEL IN THE BUNK CAN CORRODE FROM MOISTURE.

Consequence: THIS CONDITION CAN RESULT IN A SHORT CIRCUIT BETWEEN CONTACTS ON THE RELAY INCREASING THE RISK OF A VEHICLE FIRE.

Remedy: DEALERS WILL REMOVE THE EXISTING RELAY AND REPLACE IT WITH A SEALED RELAY.

Reported: 1998-11-09 (November 9, 1998) · Model years: 1997, 1998, 1999

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH SPICER SPL170 55MM CENTER BERING PACKAGE. THE END YOKE RETAINING NUT CAN LOOSEN.

Consequence: IF THIS CONDITION OCCURS, THE DRIVE LINE CAN VIBRATE AND SEPARATE FROM THE VEHICLE, CAUSING VEHICULAR DAMAGE, OR PERSONAL INJURY, OR BOTH.

Remedy: DEALERS WILL REMOVE THE 55MM CENTER BEARING PACKAGE AND COUPLER SHAFT, AND REPLACE IT WITH A NEW COUPLER SHAFT AND A 60MM CENTER BEARING PACKAGE. AN INTERIM REMEDY CAN BE IMPLEMENTED BY PLACING A SPOT WELD ON THE COUPLING SHAFT THREADS UNTIL PARTS ARE AVAILABLE.

Reported: 1999-03-15 (March 15, 1999) · Model years: 1998, 1999

VEHICLE DESCRIPTION: CLASS 8 HEAVY DUTY TRUCK CHASSIS EQUIPPED WITH 16,000 LB., 18,000 LB., OR 20,000 LB. HEAVY DUTY STEERING AXLES. THE INNER WHEEL BEARING CONE FOR THE STEERING AXLE WHEEL HUB ASSEMBLY DOES NOT PROPERLY FIT ONTO THE NAVISTAR STEERING AXLE SPINDLE ASSEMBLY. IMPROPER FIT OF THE BEARING TO THE SPINDLE INCREASES THE STRESS LEVELS TO THE STEERING AXLE SPINDLE WHICH COULD CAUSE SPINDLE FAILURE.

Consequence: IF THE SPINDLE FAILS, A LOSS OF DRIVER CONTROL COULD OCCUR, INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL REMOVE THE LEFT AND RIGHT HUB/DRUM ASSEMBLIES FROM THE STEERING AXLES AND REPLACE THE INNER WHEEL BEARING CONES AND CUPS.

Reported: 2000-01-24 (January 24, 2000) · Model years: 1999

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS. THE ANTILOCK TRACTION RELAY VALVES WERE INCORRECTLY ASSEMBLED BY THE SUPPLIER. AN EXTRA CHECK VALVE WAS INSTALLED WHICH WILL NOT ALLOW THE TRACTION CONTROL SYSTEM TO FUNCTION PROPERLY.

Consequence: THE REAR BRAKES CAN BE APPLIED AUTOMATICALLY DURING A TRACTION EVENT AND NOT RELEASE UNTIL THE AIR SYSTEM PRESSURE IS DEPLETED.

Remedy: DEALERS WILL INSPECT THESE VEHICLES AND ALL ANTILOCK TRACTION RELAY VALVES FOUND DEFECTIVE WILL BE REPLACED.

Reported: 1999-03-16 (March 16, 1999) · Model years: 1999

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS, TRANSIT AND SCHOOL BUSES, EQUIPPED WITH MERITOR AIR BRAKE AUTOMATIC SLACK ADJUSTERS. SOME OF THE AUTOMATIC SLACK ADJUSTERS HAD INSUFFICIENT TORQUE APPLIED TO THE GUIDE PAWL CAP SCREW.

Consequence: WITHOUT SUFFICIENT TORQUE ON THE GUIDE PAWL CAP SCREW, THE BRAKES COULD GRADUALLY LOSE ADJUSTMENT, INCREASING THE VEHICLE STOPPING DISTANCE.

Remedy: DEALERS WILL CHECK THE TORQUE ON THE AUTOMATIC SLACK ADJUSTER GUIDE PAWL. IF THERE IS NO TORQUE, THE BRAKES WILL BE ADJUSTED AND THE GUIDE PAWL WILL BE TIGHTENED TO 15-20 FT. LBS.

Reported: 1999-05-04 (May 4, 1999) · Model years: 1999

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH DANA/SPRAGUE WINDSHIELD WIPER ASSEMBLIES. THE KNURLED PIVOT SHAFT (WHICH OPERATES THE WINDSHIELD WIPER ARM) IS WELDED TO A LEVER, WHICH CONNECTS TO LINKAGE FROM THE WIPER MOTOR. THE WELD AT THE PIVOT SHAFT TO LEVER CAN FAIL.

Consequence: SHOULD A FAILURE OCCUR DURING INCLEMENT WEATHER ON THE DRIVER'S SIDE WHILE THE VEHICLE IS IN MOTION, THE OPERATOR'S VISION WOULD BE PARTIALLY OBSCURED.

Remedy: DEALERS WILL INSPECT THE WIPER SYSTEM, CONDUCTING A "STALL" TEST TO VALIDATE THE INTEGRITY OF THE WELD. ALL WIPER ASSEMBLIES FAILING THIS TEST WILL BE REPLACED.